Digital Twin – Boosting Truck Body Throughput 2X

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Customer: Custom Truck Body Manufacturer

PROJECT SCOPE

Scale up to 100 truck bodies/month using existing setup.
Identify bottlenecks, resource gaps, and inefficiencies.
Build and validate solutions using a digital twin.
Deploy changes quickly without disrupting operations.

APPROACH

Mapped current workflow and constraints.
Built a Plant Simulation digital twin for real-time modeling.
Tested shift expansions and layout tweaks.
Implemented optimized plan in just 3 weeks.

KEY HIGHLIGHTS

2× production achieved: 100 units/month.
14-day cycle time with only 60% workforce increase.
Zero disruption and simulation-backed execution.

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Case Study

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